Numerical and experimental analysis of labyrinth seals with rhomboidal cells

The labyrinth seals are devices commonly used in turbomachinery to reduce hot gas leakages through engine clearances, which adversely affect the gas turbine performance. For this reason, in the last decades, many in-depth analyses and optimization studies were carried out on this topic using experimental, analytical and numerical approaches. In this work, an innovative rhomboidal pattern is presented, obtained through Computational Fluid Dynamics (CFD) simulations, which is more dissipative than commonly used honeycomb cells. The experiments, performed using a Test Article that reproduces a stage and the next stator of a real low-pressure turbine suitably scaled, allowed to validate the numerical results in a situation that closely approximates the real one of use. The results obtained show that the leakages flow fraction of the total mass flow rate that bypasses the blade, which is 29.4% using a honeycomb pattern, is reduced to 27% with rhomboidal cells. The experimental results also made it possible to verify that the new pattern also behaves well from a thermal point of view, giving rise to temperature differences with respect to the honeycomb of less than 1%

Influence of honeycomb structures on straight-through labyrinth seal aerodynamics

Shroud cavities in aero engines are typically formed by a labyrinth seal between the rotating turbine shroud and the stationary casing wall. To mitigate rub-in and reduce weight, the casing often features honeycomb structures above the rotor seal fins. In this paper, the aerodynamic performance of such honeycomb structures is experimentally investigated using a rotating test rig featuring both smooth and honeycomb-tapered casing walls. Measurements show that the discharge coefficient decreases for the honeycomb configuration while losses and subsequent windage heating of the flow increase. A variation in rotational speed reveals additional sensitivities to the local flow field in the swirl chamber. Numerical simulations are conducted and validated using the experiments. A good agreement between the prediction and measurements of the jet via the evolution of pressure across the sealing fins is identified. In contrast, the prediction of losses and integral parameters reveals larger deficits. Empirical correlations from available literature satisfactorily predict the leakage mass flow rate if rotation is low and if the casing is smooth. High rotation and the presence of honeycombs, however, prove challenging and reveal the potential for further improvements. We propose a simple a-posteriori correction that can capture the effect of honeycomb structures on seal discharge by accounting for changes in momentum and flow area

ANALYSIS OF THE IMPACT OF SPECIAL CONSTRUCTIONS OF GAP SEALS ON THE DYNAMICS OF CENTRIFUGAL MACHINES

The object of research: the influence of the design features of special gap seals on the dynamic characteristics of centrifugal machines. Investigated problem: harmonization of the consumption and dynamic characteristics of the seals of the rotors of high-speed machines by applying special design methods. Main scientific results: The mechanism and operating conditions of seals with floating rings are described. It is determined that the most effective from the point of view of dynamic characteristics is the variant of the semi-movable ring. Expressions for determining the conditions of angular and radial immobility of a floating ring are obtained. The design options for deformable gap seals, including deformable floating rings, deformable interwheel seals and seals with an axially movable deformable sleeve, have been investigated. The scope of their application for unique machines with high requirements for tightness and vibration reliability has been determined. Variants of the design of labyrinth seals have been investigated. The analysis shows that the dynamic properties of labyrinth seals significantly depend on the relative position of the ridges. Overlapping ridged seals have the worst dynamic performance of the labyrinth seal designs. The honeycomb seal has more favorable dynamic properties, and the well seal has the best combination of consumption and dynamic characteristics. The dynamic characteristics are especially important for the seals of high-speed rotors of centrifugal machines. The area of practical use of the research results: Enterprises that manufacture centrifugal machines: pumps and compressors. Innovative technological product: a methodology for the selection, design and calculation of special designs of gap seals with optimization of dynamic and flow characteristics. Scope of application of the innovative technological product: The obtained research results will be useful in the design and manufacture of centrifugal pumps and compressors for any parameters

Sealing in Turbomachinery

Clearance control is of paramount importance to turbomachinery designers and is required to meet today's aggressive power output, efficiency, and operational life goals. Excessive clearances lead to losses in cycle efficiency, flow instabilities, and hot gas ingestion into disk cavities. Insufficient clearances limit coolant flows and cause interface rubbing, overheating downstream components and damaging interfaces, thus limiting component life. Designers have put renewed attention on clearance control, as it is often the most cost effective method to enhance system performance. Advanced concepts and proper material selection continue to play important roles in maintaining interface clearances to enable the system to meet design goals. This work presents an overview of turbomachinery sealing to control clearances. Areas covered include: characteristics of gas and steam turbine sealing applications and environments, benefits of sealing, types of standard static and dynamics seals, advanced seal designs, as well as life and limitations issues

Analysis of Flat Plate Honeycomb Seals Aerodynamic Losses: Effects of Clearance☆

Abstract Among the various type of seals used in gas turbine secondary air system to guarantee sufficient confinement of the main gas path, honeycomb seals well perform in terms of enhanced stability and reduced leakage flow. Reliable estimates of the sealing performance of honeycomb packs employed in industrial gas and steam turbines, are however missing in literature, thus, in order to evaluate the complete characteristic curve of the seals in the wide range of working conditions, an experimental campaign was planned. This work reports the findings of an experimental campaign aimed at evaluating aerodynamic losses within honeycomb seals. Due to the generally large amount of honeycomb cells typically present in real seals, it would be convenient to treat the sealing effect of the honeycomb pack as an increased distributed friction factor on the plain top surface that is why the simplest config- uration, the honeycomb facing a flat plate, is employed in this paper. The geometry of the hexagonal cell and the investigated clearances were chosen to well represent actual honeycomb packs employed in industrial compressors. First the pressure distribu- tion within the seal was analysed verifying that downstream the first 5 rows of cells, where entrance effects are predominant, the relative pressure drop is almost constant thus the use of an equivalent friction factor is appropriate to characterize the seal. Subse- quent analysis focused on the characterization of the friction factor as function of the Reynolds number with the aim of establishing the proper geometrical scaling to achieve flow conditions similar to real turbine most critical ones. The different behaviour of the honeycomb sealing depending on the hexagonal cell arrangement and dimensions was evaluated in terms of friction factor. Comparison with results coming from a previous CFD investigation is also presented and discussed in this paper

Large Eddy Simulation of Labyrinth Seals and Rib Shapes for Internal Cooling Passges

The turbine is one of the key components in gas turbine engines. To prevent the turbine blades from being badly damaged by their harsh working environment, it is necessary to keep them cool. This can be achieved by enhancement of the heat transfer performance through internal cooling passages. However, the large quantity of flow within this internal cycle inevitably results in mass flow loss, which is a major source of loss in turbomachinery. Therefore labyrinth seals are also investigated in this study, attempting to reduce the flow leakage and further increase the turbine efficiency. Large Eddy Simulation ( LES ) is used for its capability to capture the complex unsteady flow features in this study. Different rib shapes in a fully developed ribbed channel are investigated, aiming to improve the heat transfer performance. An immersed boundary method ( IBM ) is used with LES to generate complex geometries. With the use of IBM , the range of geometries can be represented on a background Cartesian grid. To obtain the best sealing performance, an investigation is undertaken into the possibility of optimising labyrinth seal planforms using a genetic algorithm ( GA ). By making use of the large number of populations, a much faster calculation can be achieved toward the objective function. Three hundred LES calculations are carried out, and an optimised design is generated that maximises the sealing effectiveness. The optimised design shows a leakage reduction of about 27.6% compared to the baseline geometry. The optimisation process employing a GA will be continued. It is expected that automated optimisation as presented will become increasingly important in the design process of future turbomachines, particularly for flows with strong parameter interactions, with an aim to further improve the overall efficiency of gas turbines.CS

Turbomachinery Clearance Control

Controlling interface clearances is the most cost effective method of enhancing turbomachinery performance. Seals control turbomachinery leakages, coolant flows and contribute to overall system rotordynamic stability. In many instances, sealing interfaces and coatings are sacrificial, like lubricants, giving up their integrity for the benefit of the component. They are subjected to abrasion, erosion, oxidation, incursive rubs, foreign object damage (FOD) and deposits as well as extremes in thermal, mechanical, aerodynamic and impact loadings. Tribological pairing of materials control how well and how long these interfaces will be effective in controlling flow. A variety of seal types and materials are required to satisfy turbomachinery sealing demands. These seals must be properly designed to maintain the interface clearances. In some cases, this will mean machining adjacent surfaces, yet in many other applications, coatings are employed for optimum performance. Many seals are coating composites fabricated on superstructures or substrates that are coated with sacrificial materials which can be refurbished either in situ or by removal, stripping, recoating and replacing until substrate life is exceeded. For blade and knife tip sealing an important class of materials known as abradables permit blade or knife rubbing without significant damage or wear to the rotating element while maintaining an effective sealing interface. Most such tip interfaces are passive, yet some, as for the high-pressure turbine (HPT) case or shroud, are actively controlled. This work presents an overview of turbomachinery sealing. Areas covered include: characteristics of gas and steam turbine sealing applications and environments, benefits of sealing, types of standard static and dynamics seals, advanced seal designs, as well as life and limitations issues

Labyrinth seals flow field evaluation with optical methods

This work aims to perform the detailed experimental investigation of the flow field in labyrinth seal specimen using optical methods: LDA (Laser Doppler Anemometry) and schlieren visualization. Preliminary tests were performed on a stationary (rotor model with labyrinth does not move), linear – where the curvature of the specimen is omitted – measuring stand supplied by a vacuum pump. The installation makes it possible to achieve critical pressure ratios, up to two. This investigation was also supported by CFD (Computational Fluid Dynamics) calculations performed using the Ansys CFX v.17 commercial code with a flow model based on the RANS equations. Prediction scheme simulated the experimental campaign parameters. In CFD study, different types of mesh resolution were tested, with variable volume discretization in the area of labyrinth fin tip. Presented study shows challenges as well as the possibilities of flow field visualization including three-dimensional vortexes and strong jets occurring downstream the fin tips. Some limitations of LDA method application were pointed out, especially in areas of rapid fluid expansion. Moreover paper presented that schlieren method is a very efficient way of giving the turbulence structures in linear labyrinth seal fins. In the end, experimental results were compared with CFD study, which reviled the best method for labyrinth seal structures flow field simulation. Comparison of experimental and computed results showed some agreement between those two approaches. Flow visualization also allowed to understand better the flow behavior in cavities, which is crucial for design tools development.Papers presented at the 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics, Portoroz, Slovenia on 17-19 July 2017 .International centre for heat and mass transfer.American society of thermal and fluids engineers